Process for hydrogen production



FIG. I

MINIMUM OPERABLE STEAM-CARBON RATIO MOLS. H2O PER ORGANIC C ATOM Jan. 28, 1964 PER CENT REDUCTION IN MINIMUM STEAM-CARBON RATIO Edi-LEE- SODIUM CONTENT, WEIGHT PER CENT FIG.2

I I l I l CATALYST STEAM REFORMING ETHYLENE-ETHANE FEED CATALYST B (STA N DA R D) CATALYST A (STANDARD) ETHYLENE SPACE vELocr r, STD. CC/fl'L/CC. CATALYST INVENTOR.

JOSEPH F. McMAHON ATTORNEY AGENT United States Patent Ofiice 3,ll9,6b7 Patented Jan. 23, 19%4 3,119,667 PRGCESES FQR HYDRGGEN PRODUCTAGN Joseph F. McMahon, lselin, Ni, assignor, by mesne assignments, to Pullman Incorporated, a corporation of Delaware Filed Jan. 31, 19 61, Ser. No. 86,045 22 tllaims. (Cl. 233-4212) This invention relates to an improved contact material and process for the conversion of a hydrocarbon to a hydrogen-rich gas. In one aspect this invention relates to an improved process for converting hydrocarbons to hydrogen-rich gas in the presence of steam. In a more particular aspect it relates to an improved catalyst and process for the steam reforming of hydrocarbons by which the amount of steam required to achieve carbon-free reforming is substantially lower than the amount required using conventional catalysts.

Hydrogen-rich gases including those containing carbon monoxide produced by steam reforming of hydrocarbons may be used in the Fischer-Tropsch process for the synthesis of hydrocarbons boiling in the gasoline range or oxygenated organic compounds such as alcohols and ketones. These gases may also be used in hydrogenation processes, in ammonia, methanol, or isobutanol synthesis, as well as for the reduction of metallic oxides and as fuel for domestic and industrial uses.

In recent years, the chemical industry has begun to show interest in refinery gases, coke oven gases and low molecular weight normally liquid hydrocarbons as potential catalytic steam reforming feedstocks. Unfortunately, however, the conditions used in the successful catalytic steam reforming of a feedstock containing methane as its predominanthydrocarbon constituent, such as natural gas, are wholly unsuitable to successful reforming of feedstocks containing significant amounts of hydrocarbons heavier than methane and olefins, such as the feedstoclzs discussed above. When conditions suitable to natural gas reforming are used with heavier or olefinic feedstocks, carbon is produced. The formation of carbon leads to coking of the catalyst, a severe reduction of catalyst activity and utility, and plugging of the catalyst bed and equipment. Such catalyst deactivation and plugging necessitates frequent interruption of the process in order to clean and recondition, making the process commercially unattractive.

In the manufacture of hydrogen by the reaction of hydrocarbons such as methane with steam at elevated temperatures, it is generally the practice to use catalytic masses containing nickel diluted with a refractory material such as alumina in various proportions. The higher the molecular weight of the hydrocarbon to be gasified, the greater is the degree of cracking of the hydrocarbon charge to carbon. One method for reducing carbon deposition and coking is to employ high steam to hydrocarbon ratios, which expedient is essential when normally liquid hydrocarbons are employed as the feedstock. However, as the steam requirements become more severe, the commercial feasibility of the process is lessened because of the cost of steam and considerations of operability. in addition to the drawback of high steam requirements, the prior art steam reforming catalysts generally tare operable only with feedstocks which are substantially non-olefinic and sulfur-free.

It is, therefore, an object of this invention to provide a new and improved catalyst for the conversion of a hydrocarbon to hydrogen-rich gas.

Another object is to provide a new and improved catalyst for the conversion of a hydrocarbon to a hydrogen rich gas in the presence of steam, the use of which permits a decrease in the minimum operable molar ratios of steam to hydrocarbon.

Another object of this invention is to provide an improved catalyst for the conversion of a normally liquid hydrocarbon including saturated and olefinic hydrocarbons and sulfur-containing feedstocks to a hydrogen-rich gas, which catalyst minimizes carbon formation.

Another object of this invention is to provide an improved catalyst for the carbon-free steam reforming of hydrocarbons above methane at steam requirements which are significantly lower than those required when standard catalysts are used.

A further object is to provide a process for the production of a hydrogen-rich gas by steam reforming of hydrocarbons in the presence of a particular catalyst, whereby carbon formation is substantially avoided and steam requirements are drastically reduced.

A further object is to provide a process for the steam reforming of normally liquid hydrocarbons including gas oil and naphtha boiling range hydrocarbons which process is operable at relatively low steam to hydrocarbon atios.

A still further object is to provide a method for the production of a catalyst having the above characteristics and advantages in steam reforming of hydrocarbons to hydrogen-rich gas.

w Various other objects and advantages of this invention will become apparent to those skilled in the art from the accompanying description and disclosure.

The above objects are accomplished by contacting a hydrocarbon and steam in the presence of an alkalized catalyst comprising nickel and a refractory material under conditions such that hydrogen-rich gas is produced. Numerous advantages are realized by the use of the catalysts of this invention to effect conversion of hydrocarbons to hydrogen-rich gas in the presence of steam. One advantage is that steam reforming of hydrocarbons is accomplished at ratios of steam-to-hydrocarbon which are significantly lower than those required when standard steam reforming catalysts are employed. Even at these lower steam requirements, carbon deposition is substantially avoided. These advantages are particularly important when olefin-containing feeds, and normally liquid and heavy hydrocarbon feestocks are employed, since steam reforming of such feedstoclcs is thereby rendered a commercially feasible process. Thus by the process of this invention, available and relatively inexpensive feedstocks which heretofore could not be used because of the necessity of using prohibitively high steam requirements are rendered useful for steam reforming. In addition, feedstcclts currently employed may now be converted to hydrogen-rich gas at steam requirements which are significantly lower than those now employed, thereby improving the general economics of the process. The reduction of steam requirements is particularly marked and outstanding when the catalyst contains an added alkali metal compound.

The catalysts prepared and employed in accordance with the teachings of this invention contain nickel including elemental nickel or a compound of nickel such as nickel oxide, and mixtures thereof. The nickel content of the catalysts may range between about 4 and about 40 weight percent based on the total weight of the catalyst, the high nickel catalysts usually being preferred, such as, for example, those containing between about and about 30 weight percent. A second ingredient of the catalyst is an added alkaline compound of which, alkali metal com pounds, including those of sodium, lithium and potassium, are preferred. Typical examples of such compounds are the alkali metal salts of an oxygen-containing acid such as the carbonates, bicarbonates, nitrates, sulfates, silicates, oxalates and acetates of sodium, potassium and lithium; the alkali metal oxides or an alkali metal salt capable of yielding the oxides at elevated temperatures including the aforesaid salts, as well as the alkali metal hydroxides. Particularly efiicacious catalysts are those to which an alkali metal carbonate or hydroxide has been added, especially sodium carbonate and sodium hydroxide. The catalysts are prepared so as to provide a concentration of added alkali of at least 0.5 weight percent calculated as the metal, preferably at least 2.0 weight percent. The concentration of added alkali may be as high as 30 weight percent, and usually an amount below weight percent calculated as the metal, is employed.

FIGURE 1 of the accompanying drawing presents experimental data correlating percent reduction in the minimum steam-carbon ratio required for carbon-free steam reforming, with the concentration of added alkali in the catalysts of this invention.

FIGURE 2 of the accompanying drawing shows experimental data obtained with an ethylene-ethane feed using a standard commercial catalyst as a basis of comparison.

The remainder of the catalyst charge is a porous refractory material capable of maintaining high mechanical strength and possessing steam and high temperature stability. Thus, for example, this component of the catalyst may be various non-reducible or difiicultly reducible inorganic oxides such as alumino-silicates; calcium silicates; silica; zirconia; magnesia; alumina such as alpha-alumina or a form which converts to alpha-alumina under the process operating conditions; and various admixtures thereof as well as in combination with other inorganic oxides. Examples of refractory materials of the latter type are porous refractory brick and cements including chrome and hydraulic cements, which usually contain various inorganic oxides such as magnesia, calcium oxide, etc., as binding agents, combined With silica and/or alumina. From the standpoint of catalyst life, it is preferred to employ a refractory material which is substantially inert to attack by the added alkali upon prolonged use. If the refractory does contain components capable, for example, of neutralizing the added alkali, the added alkali component should be added in an amount sutficient to compensate for any loss due to neutralization and still have the net requisite amount of uncombined alkaline compound to achieve reduction of steam requirements. Thus, if it is not desired to utilize more alkali than is necessary to achieve the desired effects on reduction of steam requirements, the preferred support, from the standpoint of catalyst life, is one which is not attacked by the added alkaline compound, such as zirconia or cement-type supports which are either neutral or alkaline in the presence of the added alkaline compound.

The catalysts may be prepared by a variety of methods without departing from the scope of this invention. One method comprises depositing nickel oxide on the refractory support or carrier material by soaking the support with a nickel precursor compound such as nickel nitrate,

nickel carbonate or nickel sulfate, by forming a slurry of the support and nickel salt and agitating, or by spraying the nickel salt solution on the support. The catalyst may then be dried and/or calcined, followed by addition of the alkaline compound usually in the form of a solution, by an impregnation or soaking technique and then dried and/or calcined. Another method comprises depositing the alkaline compound on the refractory support, followed by addition of the nickel salt to the dried and/ or calcined composite. Alternatively, the catalysts may be prepared by simultaneous addition of the nickel and alkaline compound to the support.

In addition to the above methods, the catalysts employed in accordance with the process of this invention may be prepared by impregnation or incorporation of the alkaline salt in the form a a solution, slurry or solid into a mixture comprising nickel compounded with the support. The catalysts also may be prepared by admixing the three principal components in the dry state in the desired proportions Without departing from the scope of this invention.

When the precursor of the nickel and/or alkali compounds are added in the form of a solution, intermediate or final drying steps may be employed to remove the solvent such as water and are usually conducted at a temperature between about 200 and about 400 F. for between about 2 and about 30 hours. Those methods which employ a nickel salt include an intermediate or final calcination step to convert the nickel salt to nickel oxide or nickel or mixtures thereof. Calcination may be effected at a temperature between about 800 and about 1700 F., more usually at a temperature below 1200 F., in the presence of air, nitrogen, or reducing gas for between about 2 and about 36 hours. It has been found that heat treatment of the catalyst at temperatures above those ordinarily employed for calcination has a beneficial effect on the catalyst. Thus, instead of (or in addition to) the usual calcination treatment, the catalyst may be heat-treated at a temperature between about 1700 F. and about 2000 F. for between about 1 and about 36 hours, the catalysts so treated leading to further reduction of steam requirements.

The catalytic steam reforming process of this invention is applicable to a feedstock containing aliphatic and aromatic hydrocarbons from methane to higher molecular weight hydrocarbons including acyclic and alicyclic paraffinic and olefinic organic compounds such as those containing up to about 40 carbon atoms per molecule or molecular weights as high as about 560. The feedstock may be a single hydrocarbon such as ethylene, ethane, propane, propylene, hexene, hexane, normal heptane, hep tene, etc., and mixtures thereof including various petroleum fractions such as light naphtha (e.g., boiling range of about -250 F.), heavy naphtha (e.g., boiling range of about 200-400 F.), gas oil (e.g., boiling range of about 400700 F.), as well as mineral oils, crude petroleum including topped and residual oils, and refinery and coke oven gases.

The steam requirement for the steam-hydrocarbon re forming process is defined by the steam/carbon ratio, which is the number of mols of steam charged to the reaction zone per atom of carbon charged. For example, a feed gas composition of 6 mols of steam per mol of propane corresponds to a steam/carbon ratio of 2.0. For any individual hydrocarbon from methane to gasoline boiling range hydrocarbons and higher molecular weight fractions, including olefinic hydrocarbons, there is a minimum steam to carbon ratio required for the carbon-free (operable) catalytic reforming of that individual hydro carbon. Among olefinic and non-olefinic hydrocarbons as. distinct groups, the minimum operable steam to carbon ratios for individual members of the group vary in ac cordance with molecular weight. That is, as the molec ular weight of the hydrocarbon to be gasified increases,

the steam requirements also increase. Further, for any mixtures of hydrocarbons, the critical minimum amount of steam which may be used with the mixture for its carhon-free catalytic reforming is also dependent upon molecular weight and increases as the molecular weight of the mixture increases. From the standpoint of operability of any given steam reforming process including the process of this invention, there is no upper limit to the steam to carbon ratios which can be used. However, as stated above, there is a critical minimum steam to carbon ratio which is essential to the successful or carbon-free operation of such a process. As a practical economic matter, it is always preferred to operate with the lowest possible steam to carbon ratio in view of the cost of steam, and from the standpoint of operation of the process and size of equipment. Since it is highly desirable to operate close to the minimum operable amount of steam, and since the catalysts of this invention allow for successful continuous operation of the process at a steam/carbon ratio which is itself below the critical minimum value required for standard and presently employed catalysts, it is readily apparent that the catalyst and process of this invention constitute valuable advancements in the field of steam reforming of hydrocarbons.

it has been found that when conventional high nickel compounded steam reforming catalysts are employed to convert methane to hydrogen-rich gas, the molar ratio of steam to hydrocarbon is close to the theoretical value of 1.0 and is about 1.1. in addition, steam reforming of methane presents relatively no problem from the standpoint of carbon deposition, and can be converted with conventional catalysts at close to theoretical steam values with substantially no carbon deposition, although standard catalysts generally require the use of a relatively high excess of steam as a safety factor. As the molecular weight increases above that of methane, the steam requirements become progressively more severe. For example, when using a standard nickel steam reforming catalyst, the minimum critical steam/ carbon ratio for the conversion of hydrocarbons having a molecular weight from 16 (methane) to about 110 (e.g., naphtha) or higher, increases from 1.1 to about 4, the heavier hydrocarbons requiring still higher amounts of steam. For the conversion of propane (molecular weight:44) and of heptane (molecular weight :108), for example, to hydrogen-rich gas with conventional high nickel steam reforming catalysts, the minimum steam to carbon ratios are 1.5 and 3.0, respectively.

When using the catalysts of this invention, particularly for the gasification of hydrocarbons having a molecular weight above methane, the minimum operable molar ratio of steam to organic carbon, that is, the molar ratio required for the conversion of the particular feedstock to hydrogen-rich gas with substantially no carbon formation, is significantly and markedly less than the minimum operable molar ratio required for the conversion of the same feedstock in the presence of a conventional high nickel steam reforming catalyst to which no alkali metal compound has been incorporated or added. Thus, for example, when a high nickel reforming catalyst is employed to effect conversion of normal heptane to hydrogen-rich gas, the minimum operable steam/ carbon ratio is about 3, whereas substantially the same conversion is continuously effected in the presence of the catalysts of this invention at significantly lower steam requirements. The same marked decrease in steam requirements is also realized when lower and higher molecular weight hydrocarbons or mixtures thereof are employed.

When saturated hydrocarbons or fractions thereof having a molecular weight from 16 (methane) to 110 (cg, naphtha), for example, are steam reformed in the presence of the catalysts of this invention, they may be converted to admixtures of hydrogen and oxides of carbon or hydrogen-rich gas at minimum steam/carbon ratios of from 1 to about 2.0, the lower steam ratio-s within this range applying to the lower molecular Weight hydrocarbons or mixtures thereof, the higher steam ratios applying to the higher molecular weight hydrocarbons or mixtures thereof.

When olefinic hydrocarbons or feedstocks containing olefins are steam reformed with conventional catalysts, the steam requirements are even more severe than those required for paraffinic and other saturated feedstocks of about the same molecular weight, since such feedstocks tend to deposit carbon rapidly, resulting not only in loss of carbon values but also making continuous operation impossible. On the other hand, the catalysts of this invention allow continuous steam reforming of such feedstocks at steam/carbon ratios which again are significantly lower than those required when using standard catalysts. T 0 reduce the required steam/ carbon ratio for a highly olefinic feedstock, such feedstock can be partially or Wholly hydrogenated, if desired, prior to treatment by the process of this invention, such treatment being largely dependent upon economic considerations. However, due to the fact that the present catalysts permit the use of feedstocks relatively high in olefins, hydrogenation is not a necessity.

Similarly, when sulfur-containing feeds are employed, steam requirements are more severe than when sulfur-free feedstocks are utilized, sulfur tending to cause a rapid decline in the selectivity of standard catalysts and promote carbon lay down on the catalyst. Thus, presently employed high nickel steam reforming catalysts are necessarily used to effect conversions of hydrocarbon feedstocks which have been desulfurized to very low sulfur contents such as below 5 or 2 parts per million (p.p.m.). It has been found quite unexpectedly that the contact materials of this invention possess improved resistance to the usual adverse effects of sulfur-containing feeds, and may be used for the steam reforming of hydrocarbon feeds containing sulfur contents up to about 2000 ppm. Thus, for example, the process of the present invention may be used to reform naphtha fractions containing from about 50 to about 500- p.p.m. sulfur. The addition of hydrogen will usually be found beneficial where the feed contains sulfur compounds.

The process of the present invention may be effected over a relatively Wide range of operating conditions including temperatures between about 600 and about 1800 3?. When high Btu. hydrogen-containing gas is desired, the lower temperatures within this range are employed, such as between about 600 F. and about 1000 1?. Usually the feed is preheated before introduction to the catalyst bed. Thus, for example, suitable operating conditions also include initial hydrocarbon feedstock temperatures or pro-heat temperatures of about 600 F. to about 1200 F., atmospheric or superatmospheric reforming pressures, space velocities in the reforming zone of about 50 to about 1000 volumes of hydrocarbons, expressed as C, equivalents per hour per volume of reforming catalyst, the temperatures maintained in the reforming zone usually being between about 1000-1200 F. and about 1800" F.

Pre-heating of the hydrocarbon feedstock to between about 600 F. and about 1200 F. renders attainrnent and maintenance of suitable temperatures in the reforming zone easier. This is of some importance because if the feedstock necessarily contacts the catalyst at excessively low temperatures, an otherwise adequate steam to carbon ratio will not prevent carbon formation at or near the entrance to fne catalyst bed. Since catalytic steam reforming 1's endothermic and there are practical limits to the "amount of heat which can be added to maintain the suitable elevated temperatures in the reforming zone, it is preferred to pro-heat the feedstock to as high a temperature as is consistent with avoiding pyrolysis or other heat deterioration of the feedstock.

The pressure employed may vary over relatively wide limits and include atmospheric and superatmospheric pressure. With standard reforming catalysts, pressure has no significant effect upon minimum operable steam to: carbon ratios for non-olefinic hydrocarbons, but has an appreciable effect upon such ratios for olefinic hydro-- carbons. Thus, when steam reforming olefinic feed-- stocks using conventional nickel catalysts, rising reforming pressure results in increasing required minimum operable steam-to-carbon ratios. On the other hand, in using the catalysts of this invention pressure has no significant effect on minimum steam-to-carbon ratios. Therefore, when steam reforming with the alkalized catalysts of this invention, the choice of a particular o erating pressure is principally influenced by the pressure required for the hydrogen production of the present process. For many significant uses of the hydrogen production, elevated pressures are required and it is advantageous to conduct the reforming process at substantially superatmospheric pressure so as to reduce subsequent compression. Generally it is preferred to operate the catalytic reforming zone at a pressure between about and about 1000 pounds per square inch gage (p.s.i.g.), more usually at a pressure up to about 500 p.s.i.g.

Generally, space velocities in the catalytic reforming zone between about 100 and about 1000 volumes of C hydrocarbon equivalents per hour per volume of reforming catalyst are employed, and in commercial practice more usually a space velocity between 350 and about 750 is used.

In carrying out the process of this invention, the con-- tact material may be used in the form of lumps of ir regular shape, extrusions, rings, compressed pellets or powder, including layers of these various physical forms. The operation may be as a fixed bed or fluidized catalyst system. The steam required for the reforming may be premixed with the hydrocarbon feed or it may be admitted to the reaction zone through a separate line. The feed may also contain inert materials such as nitrogen. In another embodiment of the process of this invention, oxygen may be admitted ot the reaction zone such as, for example, in an amount from about 0.2 to about 0.8 mol or more per mol of organic carbon in the feed, in the form of an oxygen-rich gas or substantially pure oxygen, or air may be used. For example, air may be used when the product gas is to be utilized in the synthesis of ammonia.

The following examples are offered as a better understanding of the present invention and are not to be construed as unnecessarily limiting thereto.

EXAMPLES The specific steam reforming runs designated as rum numbers 14 below were conducted in a commercial bench scale reactor (1 inch .in diameter x 7 feet in length) positioned within a resistancefurnace having a reaction well about 2 inches in diameter, the Walls of which are adapted to be resistance heated. The reactor was divided into an upper inlet pre-heat zone and a lower outlet reaction zone. A

Hydrocarbon liquid and water were separately metered through calibrated restriction tubes at a rate in accordance with a predetermined steam to carbon ratio and space velocity. The liquids were mixed, vaporized and introduced to the upper inlet pre-heating zone of the furnace. Heating of the vaporous mixture in the pre-heating Zone was controlled to give the predetermined preheat as sensed by thermocouples placed in the reactor and its walls. The pre-heated vaporous mixture then passed in contact with the catalyst in the lower outlet zone of the reactor, the mixture being heated during its contact with the catalyst to maintain it at suitable reforming temperatures, also as sensed by thermocouples placed in the reactor and its walls.

Product gases were cooled so as to condense unreacted water and separate the non-condensible gases. The condensed water was collected and weighed and the noncondensible gases were metered through a wet-test gas meter before being vented to atmosphere. Prior to metering, the non-condensed gases passed through a back-pressure regulator by means of which a predetermined pressure was maintained in the furnace. Samples were taken or" the non ondcnsiblc gases and analyzed. Pressure drop across the catalyst bed was measured to give an indication of carbon formation as shown by a measurable change in the reactor pressure drop.

With this equipment and procedure, a series of runs "were made on ASTM grade n-heptane having less than 1 ppm. sulfur, starting at a high steam to carbon ratio and gradually reducing the ratio in successive runs until carbon formation resulted. The particular operating conditions and results are given in Table 1.

Catalyst I.--ln run numbers 1 and 2 of the following Table I, the reaction zone was charged with a 425 gram aliquot (430 milliliters) of a commercial high nickel steam reforming catalyst which had been pro-activated with an atmosphere consisting of 339 standard cubic feet per hour of water vapor and standard cubic feet per hour of hydrogen at 1800 F. and 1850 F. outlet temperature and atmospheric pressure. This pre-activated commercial catalyst is designated as Catalyst I and contains on a Weight basis: 30.3 percent nickel oxide and a refractory material containing as the principal constituents: 11.0 percent A1 0 25.5 percent SiO 3.6 percent MgO, 1.4 percent Po o; and 19.0 percent CaO.

in run numbers 3 and 4 of the following Table I, the :reaction zone was charged with 425 grams (375 milliliters) of the catalyst of this invention designated as Catzalyst H, which was prepared as follows:

Catalyst II.-A 500 gram aliquot of the same abovedescribed pre-activated commercial steam reforming cat- :alyst designated as Catalyst I and having the above composition, was calcined for 2 hours at 1000 F. and impregnated with an aqueous solution of sodium carbonate prepared by dissolving 44 grams of sodium carbonate in cc. of boiling water. The catalyst was then dried at 400 F. This procedure was repeated with another 500 gram aliquot of the same commercial pro-activated catalyst, impregnating the catalyst with the same amount of sodium carbonate. The two batches of dried sodium carbonate impregnated catalyst were combined and calcined tfor 2 hours at 1000 F The catalyst thus prepared contains the above-designated constituents in the same proportions and, in addition, 7.3 weight percent sodium carbonate (Na CO or 3.2 weight percent, calculated as sodium metal.

Table I STEAL t REFORMING OF NORAIAL HEPTANE Run No 1 2 3 I 4 Catalyst I I II II Duration, Hours 12 12 1G 2 Reactor, Inlet Temp, F 795 805 700 795 Reactor, Outlet Temp, F 1, 400 1, 400 1,450 1,440 Reactor, Outlet Pressure, 11.5. g 20 2t) 20 20 01 Space Velocity, s.e.f.h (ii/CF Catalyst 318 323 590 5"0 HzO/C Ratio, Output BaSis 3. 03 2. 53 1.33 1.1 Rate of Reactor Pressure Drop (AP) 0 0. 33 U 2.6 Increase, Inches HzO/III Product Gas Analysis, r'tIol percent:

. 71. G 00. 7 00. 0 18. 9 28. 0 23. 5 9. i d. 6 2. 5 0. 1 1.7 2. -i

1 Output O/C Ratio. 9 Operable. 3 inoperable.

The term erable as used in Table I and throughout the application is intended to mean that operation at which substantially no free carbon is deposited on the catalyst, while the term inoperable is intended to mean a steam reforming operation during which free carbon is deposited on the catalyst as observed by a rise in pressure drop. Inspection of the above data of Table I shows that, when she standard commercial steam reforming catalyst (Catalyst I) was employed, a steam/carbon ratio of about 3 was required to prevent pressure buildup or to obtain the carbon free steam reforming of normal heptane to hydrogen-rich gas. On the other hand, when using the catalyst of this invention, carbon free steam reform ng of normal heptane to hydrogen-rich gas was effected at a steam/ carbon ratio as low as 1.3. In other words, on a comparative basis, carbon free catalytic steam reforming in the presence of a standard steam reforming catalyst required more than 100 percent more steam than that required with the catalysts of this invention.

The operability of steam reforming of a sulfur-containing feed in the presence of the catalysts of this invention is illustrated by the experimental data tabulated in the following Table ll. This operation was carried out in the above-described equipment using normal heptane containing about 200 parts per million of sulfur, added as ethyl mercaptan as the feed and the above-described Catalyst H. The specific operating conditions employed and results are tabulated below.

Table II STEAM REFORMING OF n-HEPTANE CONTAINING ABOUT 200 P.P.M. SULFUR Run No. Length of period, hrs. 12 Catalyst II H O/C mol ratio (output basis) 1.9 Reactor inlet, F 780 Reactor outlet, F 1430 Reactor outlet pressure, p.s.i.g 20.0

1 Output O/C ratio. 2 Average of two gas samples, start and end of period.

The results tabulated in Table II, by which it is shown that the reaction occurred without carbon lay down, are unexpected since steam reforming of sulfur-containing feeds usually leads to rapid carbon deposition. Sulfur analysis of the dumped catalyst from run number 5 of Table II showed the catalyst to contain only 0.05 weight percent sulfur. Comparison of the data of Table II with the results obtained in run number 1 of Table I above demonstrates that the catalysts of this invention are capable of eifecting steam reforming of a sulfuncontaining feed at a steam/carbon ratio (1.9) which is still significantly lower than the minimum steam requirement (3) for the carbon-free catalytic reforming of sulfur-free feed in the presence of standard catalyst.

The following runs 6 through were conducted in a reactor consisting of a one inch diameter quartz tube fitted with an internal thermowell. In operation, cc. (12/20 mesh) catalyst was used to make up a catalyst bed eight inches in length. The catalyst bed was located below seven inches of alundum chips used as the pre-heat zone. Before the start of the runs, the 100 cc. charge of catalyst was hydrogen pro-treated for one hour at 1400 F. Water was metered through a calibrated flow meter, vaporized and mixed with pro-heat hydrogen gas at the reactor inlet. During operation, the catalyst temperature was measured at the top, middle and bottom of the catalyst bed. Efiluent gases were passed through a condenser and receiver to collect unreacted water. After measuring in a wet test meter, the product gas was then vented and efiluent gases were sampled and analyzed by gas chromatography or mass spectrogram techniques. Pressure drop across the catalyst bed was measured to give an indication of carbon formation as shown by a measurable change in the reactor pressure drop.

With this equipment and procedure, a series of runs was made at atmospheric pressure (15 p.s.-i.a.) with a typical steam reforming catalyst used as a standard, and the alkalized catalysts of this invention, using feedstocks containing ethylene. The catalysts employed in these runs were the following catalysts designated as Catalysts A and III-XII, inclusive. The operating conditions and results obtained using standard steam reforming Catalyst A are set forth in Table III, and the results obtained with Catalysts Ill-XII, inclusive, are tabulated in Table IV.

Catalyst A .This catalyst is a commercial nickel-steam reforming catalyst (Girdler Company catalyst G-56) containing on a weight basis: 16.0 percent nickel oxide and a refractory material containing as the principal constituents: 69.2 percent A1 0 3.0 percent SiO 1.2 percent MgO, 0.55 percent Fe O and 4.1 percent CaO; X-ray analysis of the alumina showed it to be the alpha crystalline form.

Catalyst HI.A 150 gram aliquot (12/20 mesh) of the above-described commercial steam reforming catalyst, designated as Catalyst A, was impregnated with an aqueous solution of magnesium nitrate in an amount sufficient to yield about 3.5 percent magnesium salt, calculated as the metal, in the finished catalyst. The solution was prepared by dissolving 56.9 grams of magnesium nitrate hexahydrate in 55 cc. of water. After thoroughly mixing, the mixture was dried in an oven at 240 F, followed by calcination for 2 hours at 1000 F.

Catalyst IV.A 150 gram aliquot (12/ 30 mesh) of commercial steam reforming catalyst, designated as Catalyst A, was calcined for 2 hours at 1000 F., and impregnated with an aqueous solution of calcium nitrate in an amount suflicient to yield about 3.5 weight percent calcium salt, calculated as the metal, in the finished catalyst. The solution was prepared by dissolving 31.8 grams of calcium nitrate tetrahydrate in 55 cc. of water. After mixing thoroughly, the mixture was dried in an oven at 240 F., followed by calcination for 2 hours at 1000 F.

Catalyst V.A 150 gram aliquot (12/20 mesh) of the same commercial steam reforming catalyst, designated as Catalyst A, was calcined for 2 hours at 1000 F., and impregnated with an aqueous solution of lithium nitrate in an amount sufiicient to yield about 3.5 weight percent lithium salt, calculated as the metal, in the finished catalyst. The solution was prepared by adding 88.7 cc. of concentrated nitric acid previously chilled in an ice bath to 58.2 grams of lithium hydroxide monohydrate. The resultant lithium nitrate trihydrate solution cc.) thus obtained was then added to Catalyst A in increments large enough to thoroughly wet the catalyst particles, drying each time at 240 F. to ensure uniformity. After the last increment of solution was added, the catalyst was dried at 240 F. and calcined for 2 hours at 1000" F.

Catalyst VI.A 200 gram aliquot (12/20 mesh) of commercial steam reforming catalyst, designated as Catalyst A, was calcined and then impregnated with an aqueous solution of potassium carbonate in an amount sufiicient to yield about 3.5 weight percent potassium salt, calculated as the metal, in the finished catalyst. The solution was prepared by dissolving 13.2 grams of potassium carbonate in 116 cc. of Water. After mixing thoroughly, the mixture was dried at 240 F. and calcined for 2 hours at 1000 F.

Catalyst VII.-A 400 gram aliquot (12/20 mesh) of the commercial steam reforming catalyst, designated as Catalyst A above, was impregnated with an aqueous solution of potassium carbonate in an amount sumcient to yield about 3.5 Weight percent potassium salt, cflculated as the metal, in the finished catalyst. The solution was prepared by dissolving 25.7 grams of potassium carbonate in 176 cc. of water. After mixing thoroughly, the mixture was dried overnight at 250 F., followed by ealcination for 2 hours at 1000 F.

Catalyst VIII.A 150 gram aliquot (12/20 mesh) of the commercial steam reforming catalyst, designated as Catalyst A, was calcined for 2 hours at 1000 F., followed by impregnation with an aqueous solution of sodium nitrate in an amount to yield about 3.5 weight percent sodium salt, calculated as the metal, in the finished 12 sodium salt, calculated as the metal, in the finished catalyst. The solution was prepared by dissolving grams of sodium carbonate in 150 cc. of water. After mixing thoroughly, the mixture was dried in an oven at 240 F., followed by calcination for 2 hours at 1000 F.

Catalyst X.A 150 gram aliquot (12/20 mesh) of the commercial steam reforming catalyst, designated as Catalyst A, was calcined for 2 hours at 1000 F., followed by impregnation with an aqueous solution of sodium car bon ate in an amount sufiieient to yield about 3.5 weight percent sodium salt, calculated as the metal, in the finished catalyst. The solution was prepared by dissolving 12.5 grams of sodium carbonate in cc. of water. After mixing thoroughly, the mixture was dried in an oven at 240 F., followed by calcination for 2 hours at 1000 F.

Catalyst XI.A 200 gram aliquot (12/20 mesh) of the commercial steam reforming catalyst, designated as Catalyst A above, was calcined for 2 hours at 1000 F., followed by the addition thereto of an aqueous solution of sodium silicate in an amount suificient to yield about 3.5 weight percent of sodium salt, calculated as the metal, in the finished catalyst. The solution was prepared by dissolving 44.5 grams of sodium silicate (Na SiO -9H O) in 74.7 cc. of water. After mixing thoroughly, the mixture was dried overnight at 240 F., followed by calcination for 2 hours at 1000 F.

Catalyst XII.A 400 gram aliquot (12/20 mesh) of commercial steam reforming catalyst, designated as Catalyst A above, was impregnated with an aqueous solution catalyst. The solution was prepared by dissolving 19.9 30 f b m t t M b t grams of sodium nitrate in 56 cc. of Water. After mixing 0 so P car m amount Su Glen 0 yle a on thoroughly, the mixture was dried in an oven at 240 F .5 weight percent sodium salt, calculated as the metal, followad by calcination f 2 hours at 10900 R in the finished catalyst. The solution was prepared by Catalyst IX.-A 300 gram aliquot (12/20 mesh) of th dissolving 33.41 grams of sodium carbonate in 204 cc. commercial steam reforming catalyst, designated as Cata- 5 Watef- After mixing thoroughly, the mixture was drled lyst A, was calcined for 2 hours at 1000" F., followed overnight at A 240 gram ahquot of the drwd by impregnation with an aqueous solution of sodium carcomposite was placed in a quartz dish and heated in a bonate in an amount sufiicient to yield 3.5 weight percent furnace at 2000 F. for 24 hours.

Table III STEAM REFORMING WITH STANDARD CATALYST A Run Number 6 7 8 0 10 11 12 13 Catalyst Number A A A A A A A A Feedstovk mol percent ethylone/30 mol percent 25 mol percent ethylene/ mol percent ethane ethane Added Alkali 0 0 Operating Conditions:

Catalyst Wei ht, grams 61.5 65.1 72. 7 67.7 50.1 09. 8 63. 5 0a. 5 Reactor Temperature, F., top. 1,259 1, 330 1, 212 1, 053 1,157 1,110 1,070 1, 050 Reactor Temperature, F., mid 1, 432 1, 435 1, 431 1, 440 1,474 1, 485 1, 437 1,429 Reactor Temperature, I12, bottom 1, 433 1, 425 1, 429 1, 425 1, 124 1, 427 1, 406 1, 409 Flow Rate:

cc. hydrocarbon [minute 69 78-95 153 170 137 100 164 153 cc. HzO/mmute 07 38 0. 02 0. 70 0. 0. 53 0. 86 1. 03 0. 74 Space Velocity: cc. C1/l1r/cc. cata1yst-- 83 94-114 184 204 164 203 196 183 Hzo/Q, ratio 3.6 5. 3 3.3 3. 3 2. 0 3. 4 4. 0 3. 2 Run time/min 121 7 120 60 120 75 120 105 Rate of Reactor Pressure Drop (AP) Increase, Inches HzO/hr 2s. 4 -150 5. 1 12 11.0 11 0. s a, 5 Product Gas Analysis, M01 Percent:

Hi 74. 7 75. s 73. 6 74. 3 73. 4 74. 6 74.1 73. 2 O0 14.8 11.2 14.9 14.3 17.4 14.4 12.7 15.3 005 10.5 13.0 11.4 11.3 9.1 10.0 13.1 10.3 0H1 0.1 0.1 0.1 0.1 0.1 0. 2 (32H; C2115 Minimum Steam/C1 ratio 4. 5 8 5-10. 7 3. 5 3. 7 2. 9 3. 7 4 3. 3 Space Velocity o1 Ethylene, cc. C1/h1./CC. eat. 58 6680 46 41 51 49 40 Table IV STEAM REFORMING WITH ALKALIZED CATALYSTS Run Number 14 15 16 17 18 19 20 21 22 23 24 25 Catalyst Number III IV V VI VII X VIII IX XI XII 70 mol 25 mol 70 mol 70 mol percent 25 mol percent percent percent percent Feedstock 25 mol percent ethylene] ethylene/ mol ethylene/75 mol ethylene/ ethylene/ ethylenc/ 75 mol percent ethane percent ethane percent ethane 30 mo] 75 mol 30 mol percent percent percent ethane ethane ethane Added Alkali Mg Ca Li K K Na Operating Conditions:

Catalyst Weight, gra1ns 71. 0 71. 0 72. 0 73.1 73.1 73. 5 71. 6 71. 6 74. 4 67. 5 71.7 67. 3 Reactor Temperature, F., top. 1,167 1,169 ,164 1,168 1,150 1,100 1,215 1,197 1,085 1,102 1,082 1,152 Reactor Temperature, F.,

niiddlc 1, 44 1, 439 1, 453 1, 445 1, 432 1, 342 1, 332 1, 457 1, 41s 1, 374 1, s Reactor Temperature, F.,

bottom 1,404 1,403 1, 410 1, 399 1,437 1,429 1,405 1,424 1,430 1 425 1,401 1,422 Flow Rate:

cc. hydrocarbon/minute- 191 153 176 150 111 128 173 204 213 155 148 134 cc. I-IzO/minutc 0.71 0. 51 0. 56 0. 38 0. 0.72 O. 0.50 0. 45 0. 90 0. 43 0. 31 Space Velocity: cc. Cr/hl 0.

catalyst. 151 HzO/C11uti0 1.5 Run t-ime/miuu cs. 1 Rate of Reactor Pressure Drop (AP) Increase, Inches HiO/hr 6. 4 Product Gas Analysis, Mol percent: 70

l 0 O 23. 7 CO2 5. 2 CH4 1. 1 @2134 CQEIB I I Minimum Steam/C1 ratio... 1. 7 Space Velocity of Ethyle C1/hr./cc. cat 113 Minimum HzO/Cl ratio for Catalyst A at about Some Space Velocity of Ethylene. 4. 5 3. 7 3. 5 (8) (9. 7) 4. 9) (5. 4 12. 4 3. 5 10, 1)

1 Estimated value for Catalyst A using Figure 1, line labeled Catalyst A.

The accompanying FIGURE 2 is a graph showing the correlation between space velocity of ethylene in ethylcue/ethane feeds and minimum steam/carbon ratios for 1e indicated conventional steam reforming catalyst designated as Catalyst A land Catalyst B (described below). The line labeled Catalyst A of FIGURE 2 is based on a plot of the experimental data of runs 6 and 8l3 of Table III extrapolated to an ethylene space velocity of Zero, the minimum steam/carbon ratio for ethane alone being about 1.3. Run number 7 of Table III shows that a relatively high space velocity of the ethylene of 66-80, and an operating steam/carbon ratio of 5.3, the carbon lay down on the catalyst was so rapid during the first 7 minutes of opcna-tion that the run had to be discontinued, showing that the operable minirmun is not below 5.3. This result demonstrates that: (l) with standard catalysts, carbon-free steam reforming of feed at high ethylene space velocities is very difiicult due to rapid plugging of the catalyst with carbon; and (2) the straight line extrapolation shown in FIGURE 2 is a reasonable method for estimating minimum steam/carbon ratios for conventional steam reforming catalysts at high ethylene space velocities since run number 7 shows the minimum ratio is not below the extrapolation line based on Catalyst A.

Inspection of the results obtained with alkalizcd Catalysts III-XII, tabulated in Table IV above, shows that in each instance the minimum steam/carbon ratio of the catalysts containing an added alkaline compound was lower than that for conventional steam reforming Catalyst A at about the same ethylene space velocity. For example, in runs 20 and 21 of Table IV, in which Catalyst X was employed, no carbon deposition on the catalyst was observable (indicated by a O-pressure drop) at a steam/carbon ratio of 2.1 and 1.5, respectively. A slight decrease in the steam ratio following run 21 caused a reactor pressure drop, indicating that the minimum steam/ carbon ratio was slightly below 1.5, the space Velocity of ethylene in this run being 61. Inspection of FIGURE 2.

shows that with conventional Catalyst A the minimum steam/carbon ratio at the same ethylene space velocity (61) is about 4.9. Since the theoretical minimum stcam/ C ratio is 1.0, the maximum reduction possible in the steam/C ratio at a space velocity of 61 is 3.9. Since the reduction of the minimum steam/C ratio actually obtained was about 3.4 (4.9 minus 1.5), it is shown that with Catalyst X, the percent reduction in minimum steam requirements was about 87 percent.

Similar inspection of the data of Table IV shows that in the case of Catalysts VXII to which an added alkali metal compound was added, the reduction of the minimum steam requirements was significantly greater than the reduction achieved with Catalyst III (runs 14 and 15) and Catalyst IV (run 16) to which magnesium and calcium compounds were added, respectively.

Another series of runs using a feed containing 70 mol percent ethylene and 30 mol percent ethane was made at atmospheric pressure (15 p.s.i.a.), using a commercial steam reforming catalyst, designated as Catalyst B, and Catalysts Xi-ILXVHI in which alkali concentration was varied. Substantially the same procedure employed in the above-described ethylene-ethane runs was employed. The operating conditions and results obtained with these catalysts are set 'forth in Table V.

Catalyst B.-This catalyst is a commercial steam reforming nickel catalyst (Girdler Company catalyst G-29) containing on a weight basis: 32.0 percent NiO; 13.9 percent Al O and Fe O on a combined basis; 25.5 percent SiO 9.9 percent MgO; and 18.7 percent 0210. The catalyst was ground to 12/ 20 mesh and calcined for 2 hours at 1000" E, and aliquots thereof were used in the preparation of the following Catalysts XIII-XVII].

Catalyst XIZI.A 200 gram aliquot of the above commercial catalyst, designated as Catalyst B, was impregnated with an aqueous solution of sodium carbonate in an amount sufficient to yield 0.5 weight percent sodium salt,

15 calculated as the metal, in the finished catalyst. The solution was prepared by dissolving 2.3 grams of sodium carbonate in 50 cc. of water. After thorough mixing, the mixture was dried overnight at 240 F, followed by 16 calcination for 2 hours at 1000 F. Analysis of this catalyst showed it to contain 5.3 weight percent sodium, calculated as the metal.

Catalyst X VIII.-A solution of sodium hydroxide was calcination for 2 hours at 1000 F. 5 prepared by adding 2000 grams of sodium hydroxide pel- Cata1ystXlV.-A 200 gram aliquot of the above comlets to 3400 cc. of de-ionized water and heating in an mercial catalyst, designated as Catalyst B, was impregnated oven at ISO-190 F. There were then added to this soluwith an aqueous solution of sodium carbonate in an tion 3000 grams of the above-described commercial Cataarnount sufiicient to yield about 1.5 weight percent sodium lyst B, maintaining the mixture at 180-190 F. for 2 hours salt, calculated as the metal, in the finished catalyst. The with occasional stirring. Excess sodium hydroxide solusolution was prepared by dissolving 7.14 grams of sodium tion was then decanted and the catalyst dried overnight at carbonate in 50 cc. of water. After thorough mixing, the 240 F., followed by calcination for 2 hours at 1000 F. mixture was dried overnight at 240 F., followed by cal- Analysis of this catalyst showed it to contain 5.6 weight cination for 2 hours at 1000? F. percent sodium, calculated as the metal.

Table V STEAM REFORMING OF ETIIYLENE-E'IHANE FEED Run Number 27 28 20 30 31 32 33 34 35 30 37 Catalyst Number B XIII XIV XV XVI XVII XVIII Feedstock 70 mol percent ethylene/30 11101 percent ethane Concentration o! Added Alkali,

weight percent 0 0. 5 1.5 .5 3. 5 5.3 5.0

Operating Conditions:

Catalyst Weight, grams 102.1 102.1 104.0 104.0 102.2 102.2 104.2 104.2 104.2 107.3 107.3 00. 7 00.7 Reactor Temperature, F., top 1,101 1, 087 1,130 1,105 1,150 1,170 1,150 1,273 1,270 1,343 1,353 Reactor Temperature, F.,

middle 1,368 1,380 1,377 1,350 1,337 1,334 1,3s0 Reactor Temper bottom 1,423 1,429 1,410 1,415 1,424 1,427 1,420 1,423 Flow Rate:

cc. hydrocarbon/minute. 44 60 75 07 77 00 120 130 v 146 132 123 130 127 cc, Ego/minute 0.72 0.50 0. 72 0. 73 0.71 0.60 0.66 0.71 0.54 0.50 0.35 0. 00 0.43 Space Velocity of Feed: cc. Cr/hr/cc.

catalyst 53 23 01 110 03 113 144 150 176 150 147 103 152 Space Velocity of Ethylene in Feed 37 e0 63 81 65 32 100 100 123 111 103 114 107 mole, ratio .1 11.0 5.7 6.3 5.0 0.1 4.8 3.7 3.7 2.5 2.5 1.0 3.0 2.3 Run time/minutes 135 47 70 120 90 165 120 130 125 120 73 120 1.0 Rate of Reactor Pressure Drop (AP) Increase, InchesHgO/hl' 0 40.2 0 1.3 0 1.9 '0 2.4 0 0 5.2 0 2.0 Product Gas Analysis, M01 percent- 11, 74.7 74.7 75.4 74.1 74. 7 74. 0 73.2 73.1 71. 0 70.3 71.1 71.1 71.1 5.0 7.4 7.0 0.5 7.6 10.1 11.0 12.2 14.0 14.7 10.5 13.3 10.2 20.3 17.0 15.7 16.4 17.7 15.8 14.4 13.7 12.5 12.7 8.0 13.4 0.1 0.1 0.1 0.2 Trace 0.3 0.4 0.0 0.1 0.1 0.1 0.1 0 11,, 1 1 1 0.5 0.7 1 6 1.8 1.0 1.2 0.0 Estimated minimum 1110/01 ratio at the indicated ethylene space velocity, based on rate of reactor pressure drop increase 7. 0 5. 1 4. 9 3. 8 1 2. 5 2. 1 2. 4

1 A slight decrease in steam/Ci ratio caused reactor pressure drop, indicating the actual minimum steam/C1 ratio to be slightly below 2.5.

2 Operable. 3 Inoperable.

Catalyst X V.A 200 gram aliquot of commercial catalyst, designated as Catalyst B, was impregnated with an aqueous solution of sodium carbonate in an amount sufficient to yield 2.5 weight percent sodium in the finished catalyst. The solution was prepared by dissolving 11.8 grams of sodium carbonate in 50 cc. of water. After thorough mixing, the mixture was dried overnight at 240 F, followed by calcination for 2 hours at 1000 F.

Catalyst X VI.A 200 gram aliquot of the above commercial catalyst, designated as Catalyst B, was impregnated with an aqueous solution of sodium carbonate in an :amount sui'ficient to yield 3.5 weight percent sodium salt, calculated as sodium metal, in the finished catalyst. The :solution was prepared by dissolving 16.8 grams of sodium carbonate in 50 cc. of water. After thorough mixing, the mixture was dried overnight at 240 F., followed by calcination for 2 hours at 1000 F.

Catalyst X VII.A solution of sodium carbonate was prepared by adding 29.5 grams of sodium carbonate to 50 cc. of water, an additional cc. of water and heating being necessary to obtain complete solution of the sodium carbonate. This solution was then added to a 200 gram aliquot of the above-described commercial Catalyst B in two increments, mixing thoroughly each time and drying :at 240 F. hetween the additions of the solution. The Ainalmixture was dried overnight at 240 F., followed by Run numbers 26 and 27 of Table V above are bamd on the use of standard Catalyst B to which no alkali was added. In run number 26 no rise in reactor pressure drop was observable, indicating that the operating steam/C ratio of 11.0 at an ethylene space velocity of 37 was an operable ratio, that is, a steam/C ratio at which no observable carbon deposition was observed. On the other hand, in run number 27 a rapid rise in reactor pressure drop was observed at a steam/C ratio of 5.7 at an ethylene space velocity of 60, indicating a rapid carbon lay down on the catalyst under these conditions. A correlation between minimum steam/C ratios and ethylene space velocity for Catalyst B is shown by the straight line extrapolation of FIGURE 2 (labeled Catalyst B) and is based on an interpolation between the operable and inoperable steam/C ratios of runs 26 and 27, adjusting for the rate of pressure drop rise. The remaining runs of Table V are based on the use of Catalysts XIII- XVIII containing concentrations of sodium from 0.5 to 5.6 weight percent. In the case of Catalysts XIII, XIV, XV, XVII and XVIII, two runs are given in each instance, an operable (no observable rise in reactor pressure drop) and an inoperable (observable rise in reactor pressure drop). The operable runs show that the minimum H O/C ratio is below the H O/C ratio actually employed at the indicated space velocity of ethylene. On the other hand,

the inoperable run (carbon deposition) shows that the. minimum operable H O/C ratio must be above the H O/C ratio actually employed at the particular ethylene space velocity. Therefore, in each instance the minimum Ego/C1 ratio required to obtain carbon-free steam reforming ranges between the operable and inoperable H O/C ratios indicated for each of the catalysts. In the case of Catalyst XVI, employed in run number 34, no rise in re-. actor pressure drop was observed at an H O/ C ratio of 2.5 and a space velocity of ethylene of 123. However, a

slight decrease in the H O/C ratio caused a rise in reactor pressure drop, indicating that the minimum H O/C ratio was slightly below 2.5. Thus, for Catalyst XVI, the minimum H O/C ratio at an ethylene space velocity of '123" is taken as 2.5. For this purpose of convenience, the

results obtained in the runs of Table V are re'tabulated in Table VI, in which each of the alkalyzed catalysts is compared with standard Catalyst B at the same ethylene space velocity.

18; the steam/C ratio about 3 weight percent added alkaliis required. Reductions in steam/C ratio obtained with other feedstocks alsoagree with the curve shown in FIG- URE l as illustrated by the data obtained with hep tane given in Table I. As described above, the data of Table I are based on the use of a pro-activated commercial steam reforming catalyst similar to commercial Catalyst B. Run numbers 3 and 4 of Table I show that with Catalyst II, which contained about 3.2 weight percent added sodium, the operable and inoperable steam/C ratios were 1.3 and 1.1, respectively. Since the minimum steam/C ratio for standard commercial Catalyst I; used in runs 1 and 2 of Table I, isbetween 2.5 (inoperable) and 3 (operable), or about 2.7, the percent reduction in the steam/C ratio achieved when using heptane at about 3.2 percent sodium is between 82 percent (based on the operable ratio) and 94-percent (based on the in-v operable ratio). A plot of this range in the percent reduction of minimum steam/C ratio is shown'in FIGURE Table VI CORRELATION OF PERCENT REDUCTION IN STEAM REQUIREMENTS WITH ALKALI CONCENTRATION Operable Percent Inoperable Range of Concenreduc- Percent percent tration tion in reduction reduction of steam/C1 in steam/Ci in steam/ Added Ethylene ratio Ethylene ratio based C1 ratio Sodium Steam/C1 space based on Steam/Cr space on in- (below in- (weigh? ratio Velocity opegable ratio Velocity opeable opierable percen ra 10s ra lOS an a ove operable) Catalyst XIII 0.5 6.3 63 5 81 CatalystB 0 7.3 as i 16 i 9.1- 81 i 51 16-51 Catalyst XIV 1. 5 6.1 65 4. 8 82 CatalystB 0 7.5 65 i 22 i 9.2 82 i 52 22-52 Catalyst XV 2. 5 3. 7 100 I 3. 7 109 CatalystB 0 11 100 i 73 t 11.9 109 i 75 73-75 Catalyst XVI 3. 5 2. 5 123 1 2. 5 123 CatalystB o 13.3 123 i 88 i 13.3 123 l 88 88 Catalyst XVII 5.3 2.5 111 1.9 103 CatalystB 0 12.1 111 i 86 11.3 103 i 91 86-91 Catalyst XVII-I 5.6 3 114 2. 3 107 CatalystB 0 12.4 114 i 32 i 11.7 107 l 88 82% A slight decrease in steam/C1 ratio caused reactor pressure drop, indicating the actual minimum steam/C ratio to be slightly below 2.5.

In Table VI, the operable steam/C ratios given in column 2 at the ethylenespace velocity given in column 3 for Catalysts XIIIXVIII are the experimental values shown in Table V. The inoperable steam/C ratios in column 5 at the ethylene space velocities given in column 6 for Catalysts XIII-XVIII also are the experimental yalues set forth in Table V. In each instance, the cor-responding operable and inoperable steam/C ratios for standard CatalystB are given at the same ethylene space velocity as determined by the straight line entrapoiaticn of FIGURE 2 (line labeled Catalyst B). The percent reduction in the steam/C ratios effected at the various concentrations of alkali in Catalysts XIII- XVIII are given in columns 4 and 7 of Table VI. The percent reduction in the steam/C ratios of column 4 are based on the steam/C ratios at which no observable carbon was deposited on the catalyst (operable). The percent reduction in steam/C ratios of column 7 are based on the steam/C ratios at which carbon was depositing or plugging the catalyst (inoperable). The range of percent reduction in steam/C ratios are summarized in column 8 of Table VI, a plot of which is given in the accompanying FIGURE 1 correlating the percent reduction in the minimum steam/ carbon ratios with alkali concentration. Inspection of FIGURE 1 shows that at an alkali concentration of about 2 weight percent, better than percent reductions in minimum steam/carbon ratios are obtained and that for maximum reduction of l by the line labeled heptane,- and showsthat at an alkali concentration of about 3.2 percent, the percent reduction in minimum steam/C ratios is at least182 percent, which was also indicated for the ethylene-ethane feed. FIGURE 1 also shows that when the catalysts of this invention are used to steam reform a propylene: propane feed with a catalyst containing 5.6 percent alkali; the percent reduction in minimum steam/C ratio is at least 93 percent. The data on which the line labeled propylene-propane of FIGURE 1 is based are set forth in Table VII below.

Aging studies on Catalysts XIII-XVII, in which the alkali concentration was varied indicated that the addi-' tion of sodium in excess of 1.5 weight percent asin Catalysts XVI and XVII resulted in a catalyst which retained its catalytic properties under adverse conditions.- In these tests the catalysts were contacted with ethylene.- ethane feed after they had been treated with steam at 1' atmosphere pressure and 1500 F. for various periods of time. Catalyst XVI to which 3.5 weight percent sodium was added resulted in good .rnaintenance of the effect on reduction of steam requirements after treatment for 10G hours at 1500" F. with steam. Substantially no change in the initial minimum steam/C ratio was observed when Catalyst XVII, containing 5.3 weight percentadded' sodium, was treated with steam at 1506 F. for hours. 1

A series of runs was made using propylene-propane feed with conventional steam reforming catalyst, designated as Catalyst I above, and with Catalyst XVIII, containing 5.6 weight percent added sodium prepared as described above. These runs were conducted in the commercial bench scale unit described above in connection with the operating procedure employed in runs 1-5. The specific operating conditions employed and the results obtained are set forth in the following Table VII.

20 for minutes with 1 liter of water and filtered each time. The above steps were repeated, obtaining a second filter cake. The two filter cakes (1803 grams) were combined and an aqueous solution of nickel nitrate prepared by dissolving 240 grams of Ni(NO -6H O in 40 cc. of water was added thereto with thorough mixing. An aqueous solution of sodium carbonate was prepared by dissolving 30 grams of sodium carbonate in 140 cc. of water, adding Table V1l STEAM REFORMING OF PROPYLENE-PROPANE FEED Run Number 39 40 41 42 43 Catalyst Number I XVIII Feedstock mol percent propylene/80 mol percent propane Added Alkali 0 5.6 weight percent sodium t l O Stream Hours Prior to gk im n 282 480 514 Operating Conditions:

Reactor Inlet Tempeature. F 650 665 980 940 895 Reactor Outlet Temperature, F 1, 450 1, 445 1, 395 1, 437 1, 456

Reactor Outlet Pressure, p.s.l.g 126 124 125 225 125 01 Space Velocity, SCFH Ci/cu.

It. Out 294 322 409 450 374 Length of Run, Hours-. 12 12 1O 4 6 11 0/61 ratio 1 4 11.1 1. 7 1. 5 1. 9

Rate of Reactor Pressure (AP) In- 0.0 0.38 0 o 0 crease, Inches H10] (Operable) (inoperable) (Operable) (Operable) (Operable) Product t Gas Distribution, Mol

1552: 76. o 75. 9 64. 0 s1. 2 s7, 2 CO---" 4.3 5.9 17.9 15.0 17.5 C0 18. 2 1. 81 9. 4 10.5 9. 0 0H 0. 1 0. 1 8. 7 13. 3 o. 3 Minimum 1110/01 ratio- 11. 7 11.7 I 1.7 or less 1.5 or less 1.9 or less Pe Ce 1; Reduction in {no ii, rntin At least 93% 1 This value is based on the average 1110/01 ratios of Runs 39 and 4 0 I Since no plugging of catalyst was observed at the indicated HzO/Ci ratio, the minimum ratio is below the actual operating HZOIC; ratio employed in the experiment.

Comparison of the results obtained with Catalyst XVIII of this invention employed in runs 41, 42 and 43 of Table VII with standard Catalyst I used in runs 39 and 40, shows that the propylene-propane feed was converted to hydrogen-rich gas at a steam/carbon ratio which was at least 93 percent lower than the minimum required when using the standard catalyst, the standard catalyst requiring a steam/C ratio of at least 11.7 to obtain carbon-free reforming of this olefinic feed, Catalyst XVIII requiring a minimum steam-carbon ratio which is less than 1.7. These data show the striking improvement in the steam reforming of difiicultly reformed feeds such as propylenepropane, an available refinery stream, which is realized by the catalysts of this invention. The percent reduction (at least 93 percent) in minimum steam/carbon ratios achieved at an added sodium content of 5.6 weight percent using this propylene-propane feed, is shown in FIG- URE 1 by the vertical line labeled propylene-propane.

Additional catalysts of the present invention are the following Catalysts XIX and XX in which zirconia and chrome cement were used as the refractory materials. These catalysts were used to steam reform a feed containing 70 mol percent ethylene and mol percent ethane at atmospheric pressure (15 p.s.i.a.) using the same type procedure described above in regard to the other runs involving this feed. The specific operating conditions employed and the results obtained are given in Table VIII.

Catalyst X IX .A solution of zirconium nitrate was prepared by dissolving 188 grams of ZrO(NO -2H O in 2000 cc. of de-ionized water. A dilute solution of arnmonium hydroxide (1000 cc.) prepared by adding 250 cc. of concentrated ammonium hydroxide to 2000 cc. of water was added to the zirconium salt solution with rapid stirring in increments of 100 cc. every two minutes until 1000 cc. were added. The final pH of the mixture was 9.25. The solution was stirred for an additional 15 minutes and then filtered. The filter cake was slurried twice this solution to the nickel nitrate-filter cake mixture. The entire mixture was then blended until a smooth mixture was obtained. The mixture was then placed in an oven and dried at 240 F. for three days, calcined for 2 hours at 1000 F. and screened to 12/20 mesh. The 12/20 mesh catalyst was then steam-aged at 1500 F. for a total of 137 hours. The resultant catalyst contains about 3.5 weight percent sodium and about 20 weight percent nickel supported on zirconia.

Catalyst XX .-A nickel nitrate solution was prepared by dissolving 507 grams of Ni(NO -6H O in 1500 cc. of water. A solution of 300 grams of sodium carbonate in 2000 cc. of water was added to the nickel nitrate solution in increments of cc. every two minutes with vigorous stirring until a pH of 9.0 was reached. The mixture was filtered, and the filter cake was washed three times by placing the cake in a beaker, adding 1 liter of water and stirring vigorously with a mechanical stirrer for 15 minutes. Enough water (50 cc.) was added to the washed filter cake to bring it to a proper consistency for blending in the refractory material. The refractory material employed was H. W. Chrome Castable Cement which, upon analysis, was shown to contain, on a weight basis: 6.8 percent silica; 31.2 percent alumina; 0.4 percent titania; 0.9 percent Fe O 11.3 percent FeO; 5.9 percent calcium oxide; 15.8 percent magnesia; 26.7 percent chromic oxide; and zero percent alkali metals. 280 grams of this cement in powdered form was added to the nickel carbonate filter cake in small increments and blended in thoroughly. The resulting mixture was then spread to approximately one-half inch in thickness and, when sulficiently dry, was cut into cubes of about one-fourth to onehalf inch and allowed to dry overnight at room temperature. These cubes were then dried in an oven at 240 F. for about 24 hours, followed by calcination for 2 hours at 1000 F. The cubes were broken up and ZO-mesh material was pelleted. The pellets were then broken up and Table VIII Run Number 44 45 46 47 Catalyst Number XIX XX 70 mol percent ethylene/30 mol Feedstock percent ethane Support Zirconia Chrome cement Operating Conditions:

Catalyst Weight, grams Reactor Temperature, F., top Reactor Temperature, I

middle Reactor Temperature, F., bottom Flow Rate:

cc. hydrocarbon/minute cc. HzO/minute Velocity: cc. Cilhn/cc. alyst 1120/01 ratio Run time, minut Rate of Reactor Pressure Increase, Inches HiO/I-Ir Procgict Gas Analysis, M01 Percent:

(121-14. CzHu Minimum HzO/C ratio Space Velocity of Ethylene Estimated Minimum 1120/01 ratio for Catalyst B at about same ethylene space velocity Percent Reduction in um Steam/O1 ratio effected 1 Based on the correlation shown in Figure 1,1inelabeled Catalyst B. 2 Operable. B inoperable.

The data of Table VIII show that the alkalized nickelzirconia catalyst (Catalyst XIX) etfected steam reforming of the ethylene-ethane feed at a minimum steam/C ratio of about 2.1 at a space velocity of ethylene of about 121. On the other hand, standard nickel Catalyst B requires a minimum steam/C ratio of 13.1 at the same ethylene space velocity (121) as estimated from the straight line extrapolation of FIGURE 2 (line labeled Catalyst B). Thus, with Catalyst XIX, at an alkali concentration of about 3.5, the percent reduction and minimum steam/C ratio which was efiected is about 90 percent. Approximately the same percent reduction in steam/C ratio was effected, using the alkalized nickel-chrome cement catalyst (Catalyst XX). It is noted that zirconia-based Catalyst XD( is a very stable catalyst as shown by the fact that, although it had been aged by treatment at 1500 F. for 137 hours with steam prior to use, it efiected a 90 percent reduction in the minimum stearn/ carbon ratio.

It is well known that high molecular weight hydrocarbon oils are only difficultly converted to hydrogen-rich gas by steam reforming. It has been found that such high molecular weight hydrocarbon oils are successfully converted to hydrogen-rich gas in the presence of steam, using the catalysts of this invention, at steam/C ratios which render the steam reforming of such oils commercially feasible. This is demonstrated by the use of the following Catalyst XXI t eilect steam reforming of a parafiinic mineral oil having a molecular weight of 310. The test procedure employed was substantially the same as that described above in connection with runs 1-4. The

22 specific operating conditions and results obtained are tabulated in the following Table TX. The inspections on the paraifinic mineral oil employed are as follows:

INSPECTIONS OF PARAFFINIC MINERAL OIL FEED Assumed formula C E-I Catalyst XXI.A 500 gram aliquot of the same abovedescribed preactivated commercial steam reforming cata lyst, designated as Catalyst I, was calcined for 2 hours at 1060" :F. and impregnated with an aqueous solution of 44 grams of sodium carbonate dissolved in cc. of boiling. Water. After mixing thoroughly, the mixture was dried at 400 F. The above steps were repeated. The two batches of catalyst were then combined, calcined for 2 hours at 1000" R, and thoroughly mixed. Chemical analysis showed the catalyst to contain 3.0 Weight percent sodium.

TABLE IX STEAM REFORMNG OF MINERAL OIL (310 Molecular Weight) Run number 48 Catalyst number XXI Total on-stream hours prior to run 114 Operating conditions:

Reactor inlet temperature, F. 700

Reactor outlet temperature, F 122 Based on correlation of minimum steam/C1 ratios and molecular weight of paraflinic hydrocarbons, a straight line relationship.

The data of Table IX show that with the catalysts of this invention the conversion of heavy oil was being effected at an operating steam/C ratio of 20' without any observable pressure drop rise. Thus, the minimum steam/C ratio is less than 20. On. the other hand, with standard Catalyst 1, the minimum steam/C ratio is about 39.

Additional experiments using the catalysts of this invention were performed using catalysts prepared by the method illustrated by the preparation of the following 23 Catalyst XXII. The results obtained with this catalyst using ethylene-ethane feedstocks at atmospheric pressure (15 p.s.i.a.) are tabulated in the following Table X, the data of which further show the superiority of the catalysts of this invention for steam reforming of olefinic feeds as compared with standard Catalyst B.

Catalyst XXIL-A 25 gram aliquot of Catalyst B was soaked in 50 cc. of water for 2 hours at 180200 F. The excess water was then decanted and the wet catalyst was placed on filter paper to absorb the balance of excess water. The water-soaked catalyst was then weighed to determine the weight of water absorbed (6.5 grams). Therefore, a 200 gram aliquot of Catalyst B would absorb 52 grams of water. Based on this determination, a 200 gram aliquot of Catalyst B was then soaked in 156 cc. of an aqueous solution containing 50.4 grams of sodium carbonate. The catalyst absorbs 52 grams of solution'or 16.8 grams of sodium carbonate, which yields a finished catalyst containing about 3.5 weight percent sodium. The mixture was heated at 1802 F. for 2 hours with occasional stirring, followed by decantation of excess liquid, placing the soaked catalyst on filter paper to absorb excess water. The catalyst was then heated at 240 overnight with occasional stirring, followed by calcinatron for 2 hours at 1000 F.

Table X Run Number 49 50 Catalyst Number XXII Feedstock 70 mol percent ethylens/30, mol percent ethane Operating Conditions:

Catalyst Weight, grams. 107. 3 107. 3 Reactor Temperature, F., top 1,277 1,276 Reactor Temperature, 17., middle 1,277 1,276 Reactor Temperature, F., bottom 1,423 1,422 Flow Rate:

cc. hydrocarbon/minute 134 113 cc. Biro/minute 0. 43 0.29 Space Velocity: cc. Oi/hr lcc catalyst 160 135 HgO/C ratio 2. 2 1. 7 Run time, minutes 120 35 Rate of Reactor Pressure Drop (AP) Increase,

Inches HzO/Hr 0 2 9. 6 Product Gas Analysis, Mol percent:

C H 1 0 0.5 Minimum Steam/C1 ratio 2. 0 Space Velocity of Ethylene, cc. C1/hr./CC. cat 112 95 Minimum HQO/Cl ratio for Catalyst B at about same Space Velocity of Ethylene 10. 4

l Operable. 1 Inoperable.

The results obtained with Catalyst XXII prepared in accordance with the above so-called soaking techniques compares favorably with the results obtained with Catalyst XVI (refer to run number 34 of Table V) prepared by the so-called impregnation technique.

Catalyst XXIII.-A 150 gram aliquot of standard Catalyst A, described above, was calcined for 2 hours at 1000 F. and then impregnated with an aqueous solution of potassium carbonate in an amount sufficient to yield 3.5 weight percent potassium in the finished catalyst. The solution was prepared by dissolving 12.8 grams of potassium carbonate in 55 cc. of water. After mixing thoroughly, the mixture was dried in an oven at 240 F., followed by calcination for 2 hours at 1000 The alkalized catalysts of this invention also are unexpectedly effective and improved catalysts for the production of high B.t.u. Towns gas from hydrocarbon feedstocks at steam levels which are significantly lower than those required with conventional catalysts. For the production of Towns gas, temperatures between about 600 and about 1000 F. are suitable. For example, above Catalyst XXIII (71.7 grams) was used to convert propane to a high B.t.u. product, the operating conditions being: atmospheric pressure (15 p.s.i.a.); reactor temperature, top, middle and bottom: 835 F, 964 F. and 931 F., respectively; flow rate: 127 cc. propane/minute, 0.53 cc. steam/minute; space velocity: 228 cc. C /hour/ cc. catalyst; steam/C ratio: 1.9 and run time: 205 minutes. Under these conditions the rate of reactor pressure drop increase was zero inches water/hour. The product gas analysis showed it to contain, on a mol percent basis: 56.5 H 4.6 CO; 18.7 CO 19.0 CH and 1.2 C H the B.t.u./s.c.f. value on a C and CO -frec basis being 486. Carbon-free reforming was also obtained at reactor temperatures of 779 F. (top), 860 F. (middle) and 836 F. (bottom) and a steam/C ratio of 1.7. On the other hand, standard Catalyst A is inoperable at these tempera ture (908 F. top, 1008 F. middle, 912 F. bottom) and an H O/C ratio of 1.6 because of rapid deposition of coke on the catalyst, indicated by a rate of reactor pressure drop increase of 70 inches of steam/hour. Based on this rate of carbon lay down on the catalyst, the estimated minimum steam/C ratio is approximately 3.8.

As apparent from the above, a markedly improved catalyst and process for the conversion of hydrocarbons, particularly hydrocarbons having a molecular weight above that of methane, to hydrogen and oxides of carbon is provided by the present invention. The process is operable at significantly lower levels of steam concentration than required with standard nickel steam reforming catalysts. The process is also applicable to the conversion of feedstocks which are at best only difiicultly reformed even at high steam/carbon ratios in present day processes such as olefinic and normally liquid hydrocarbons and sulfur-containing feedstocks. The term alkaline metal compound as used herein is intended to include the alkali metal and alkaline earth metal compounds and, of these, the alkali metal compounds are preferred because of their vastly superior effect on reducing minimum steam requirements.

In accordance with the preferred embodiment of this invention, the steam reforming zone is charged with the catalyst to which an alkali metal salt has been added including salts of an oxide of carbon such as potassium, sodium and lithium carbonates and bicarbonates and mixtures thereof, and the alkali metal hydroxides, sodium carbonate and hydroxide being particularly effective. The reduction of minimum steam/ carbon ratios becomes particularly marked at alkali metal contents of at least about 2 weight percent, maximum reduction (e.g., above percent) being realized at concentrations of added alkali metal of at least 3 weight percent. It is to be understood that the term catalyst as employed herein is intended to include the contact mass as prepared and charged to the reaction zone, that is, for example, in the form of nickel or nickel oxide in combination with sodium carbonate and the difiicultly reducible refractory support material, as well as any modified physical or chemical form to which the contact mass may be converted during the course of the steam reforming process. Mixtures of the alkaline metal compounds can also be employed. Hence the use of such mixtures is contemplated by and within the scope of this invention.

This application is a continuation-in-part of my prior and co-pending application S.N. 11,952, filed March 1, 1960, now abandoned.

Various alterations and modifications of the catalysts and process of this invention may become apparent to those skilled in the art without departing from the scope of this invention.

Having described my invention, I claim:

1. A process for the reforming of a hydrocarbon with steam to produce hydrogen which comprises contacting steam and a hydrocarbon in the presence of a catalyst comprising nickel and a refractory material and contain- 25 ing at least 0.5 weight percent of an added alkaline metal compound, calculated as the metal, at an elevated temperature such that hydrogen is produced.

2. A process for the reforming of a hydrocarbon with steam to produce hydrogen which comprises contacting steam and a hydrocarbon in the presence of a catalyst comprising nickel, a refractory material and at least 0.5 Weight percent of an alkmi metal compound, calculated as the metal, at an elevated temperature such that hydrogen is produced.

3. A process for the conversion of a hydrocarbon having a molecular Weight above that of methane in the presence of steam to produce hydrogen which comprises contacting steam and a hydrocarbon having a molecular Weight above that of methane with a catalyst comprising nickel, a refractory material and at least 0.5 weight percent of an alkali metal compound, calculated as the metal, at an elevated temperature under conditions such that hydrogen is produced as a product of the process and substantially no free carbon is deposited.

4. A process for theconversion of a normally liquid hydrocarbon in the presence of steam to produce hydrogen which comprises contacting steam and a normally liquid hydrocarbon with a catalyst comprising between about 4 and about 40 weight percent nickel, a refractory material and at least 0.5 and less than 20 weight percent of an alkali metal compound, calculated as the metal, at an elevated temperature under conditions such that hydrogen is produced as a product of the process and substantially no free carbon is deposited.

5. A process for the reforming of an olefin-containing feed in the presence of steam to produce hydrogen which comprises contacting steam and an olefin-containing feed with a catalyst comprising between about 4 and about 40 weight percent nickel, a refractory material and at least 0.5 and less than 20 weight percent of an alkali metal compound, calculated as the metal, at an elevated temperature under conditions such that hydrogen is produced as a product of the process and substantially no free carbon is deposited.

6. A process for the reforming of a sulfur-containing hydrocarbon feed in the presence of steam to produce hydrogen which comprises contacting steam and a sulfurcontaining hydrocarbon feed with a catalyst which cornprises nickel, a refractory material and at least 0.5 weight percent of an alkali metal compound, calculated as the metal, at an elevated temperature under conditions such that hydrogen is produced as a product of the process and substantially no free carbon is deposited.

7. A process for the reforming of hydrocarbons heavier than methane with steam to produce hydrogen which comprises contacting steam and a feed comprising as the predominant components hydrocarbons heavier than methane, with a catalyst comprising between about 4 and about 40 weight percent of a member of the group consisting of elemental nickel, nickel oxide and mixtures thereof, at least 0.5 and less than 20 weight percent of a sodium compound, calculated as the metal, and a refractory support as the remainder of the catalyst, at a temperature of between about 600 F. and about 1800" P. such that hydrogen is produced as a product of the process.

8. A process for the conversion of a hydrocarbon in the presence of steam to produce hydrogen which comprises contacting steam and a hydrocarbon with a catalyst comprising nickel, zirconia, and at least 0.5 weight percent of an alkali metal compound, calculated as the metal, at an elevated temperature under conditions such that hydrogen is produced.

9. A process for the conversion of a hydrocarbon in the presence of steam to produce hydrogen which comprises contacting steam and a hydrocarbon with a catalyst comprising between about 4 and about 40 weight percent nickel, a porous cement as a support and at least 0.5 and less than 20 weight percent of an alkali metal compound,

26 calculated as the metal, at an elevated temperature under conditions such that hydrogen is produced.

10. A process for the conversion of a hydrocarbon inthe presence of steam to produce hydrogen which comprises charging a catalyst comprising a member of the group consisting of elemental nickel, a compound of nickel and mixtures thereof, an added alkali metal salt of an oxygen-containing carbon acid and a refractory material, to a steam reforming zone and contacting a mixture of steam and hydrocarbon with said catalyst at an elevated temperature such that hydrogen is producedas a product of the process, said catalyst containing at least 0.5 weight percent combined alkali metal.

11. A process for theconversion of a hydrocarbon in the presence of steam to produce hydrogen which comprises contacting steam and a hydrocarbon with a catalyst comprising a member of the group consisting of elemental nickel, a compound of nickel and mixtures thereof, and a refractory material to which catalyst an alkali metal hydroxide has been added in an amount sufficient to yield at least 0.5 and less than 20 weight percent combined alkali metal in the catalyst, at an elevated temperature such that hydrogen is produced as a product of the process.

12. A process for the reforming of a hydrocarbon feed with steam to produce hydrogen which comprises contacting a mixture of steam and a hydrocarbon feed with a catalyst comprising between about 4 and about 40 weight percent of a member of the group consisting of elemental nickel, nickel oxide and mixtures thereof, supported on a refractory material and containing at least 0.5 and less than 20 weight percent of an alkali metal compound, calculated ias the metal, at a temperature between about 606 F. and about 1800 F. to produce hydrogen as a product of the process.

13. A process for the conversion of a hydrocarbon in the presence of steam to produce hydrogen which comprises contacting steam and a hydrocarbon in the vapor phase with a catalyst comprising between about 4 and about 40 weight percent nickel, a refractory support and an alkali metal compound, said catalyst containing at least 2 weight percent alkali metal compound, at a temperature between about 600 F. and about 1 800 F. such that hydrogen is produced and substantially no free carbon is deposited on the catalyst.

14. A process for the reforming of a hydorcarbon in the presence of steam to produce hydrogen which comprises contacting steam and a hydocarbon with a catalyst comprising a member of the group consisting of elemental nickel, a compound of nickel and mixtures thereof, and a refractory material to which catalyst has been added an alkali metal carbonate in an amount sufficient to yield at least 0.5 and less than 20 weight percent alkali metal in the catalyst, at an elevated temperature such that hydrogen is produced and substantially no free carbon is deposited on the catalyst.

'15. A process for the conversion of a hydrocarbon in the presence of steam to produce hydrogen which comprises contacting steam and a hydrocarbon with a catalyst comprising between about 4 and about 40 weight percent nickel, a refractory material and containing at least 0.5 and less than 20 Weight percent sodium added as sodium hydroxide, at an elevated temperature such that hydrogen is produced and substantially no free carbon is deposited on the catalyst.

16. A process for the reforming of a normally liquid hydrocarbon in the presence of steam to produce hydrogen-rich gas which comprises charging a contact mass comprising nickel, an alkali metal carbonate and a refractory material to a steam reforming zone, said contact mass containing at least 0.5 weight percent combined alkali metal, and contacting a mixture of steam and a normally liquid hydrocarbon feed therewith in the vapor phase such that hydrogen-rich gas is produced and substantially no free carbon is deposited.

17. A process for the conversion of a hydrocarbon feed in the presence of steam to produce hydrogen which comprises charging a catalyst comprising an alkali metal carbonate, a member of the group consisting of elemental nickel, nickel oxide and mixtures thereof, and a refractory material to a reaction zone and passing steam and a hydrocarbon feed over said catalyst under conditions such that hydrogen is produced, said catalyst containing at least 0.5 weight percent combined alkali metal.

18. A process for the reforming of a hydrocarbon in the presence of steam to produce hydrogen which comprises contacting an admixture of steam and a hydrocarbon with a catalyst prepared by adding an alkali metal compound to a member of the group consisting of elemental nickel, a compound of nickel and mixtures thereof supported on a refractory material in an amount sufficient to provide substantially not lower than about 0.5 and less than 20 weight percent combined alkali metal in the catalyst, in the vapor phase at a temperature between about 600 F. and about 1800" P. such that hydrogen is produced as a product of the process.

19. A process for the reforming of a sulfur-containing feed in the presence of steam to produce hydrogen which comprises contacting steam and a sulfur-containing hydrocarbon feed with a catalyst comprising nickel, sodium carbonate and a refractory support at an elevated temperature such that hydrogen is produced as a product of the process, said catalyst containing at least 0.5 weight percent combined sodium.

20. The process of claim 2 in which said alkali metal compound is an alkali metal carbonate.

21. The process of claim 20 in which said alkali metal carbonate is sodium carbonate.

22. The process of claim 4 in which said alkali metal compound is an alkali metal carbonate.

References Cited in the file of this patent UNITED STATES PATENTS 1,736,065 Williams Nov. 19, 1929 1,943,821 Hanks et al Jan. 16, 1934 2,056,911 Schiller et a1. Oct. 6, 1936 2,430,432 Marisic Nov. 4, 1947 2,457,719 Pine et a1. Dec. 28, 1948 2,479,879 Teter Aug. 23, 1949 2,830,880 Shapleigh Apr. 15, 1958 2,972,644 Holmes et al. Feb. 21, 1961 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No, 3, 119,667 January 28, 1964 Joseph F. McMahon It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

In the grant, line 1, for "Iselin, New Jersey" read Clinton, New Jersey in the heading to the printed specification, line 3, for "Iselin, N, J," read Clinton, N, J, column 2, line 52, for "feestocks" read feedstocks column 7, line 42, for "0t" read to column 13, line 48, before "a" insert at same line 48, strike out "the"; columns 15 and 16, Table V, fourth column, line 6 thereof, for "1,987" read l, 187 column 17, line 15, for "this" read v the columns 19 and 20, Table VII, second column, line 9 thereof, for "294" read 284 same Table VII, third column, line 16 thereof, for "1,81" read 18,1 column 26, line 46, for "hydorcarbon" read hydrocarbon line 48, for "hydocarbon" read hydrocarbon Signed and sealed this 1st day of September 1964,

(SEAL) Attest:

ERNEST W, SWIDER EDWARD J, BRENNER Attesting Officer Commissioner of Patents 

1. A PROCESS FOR THE REFORMING OF A HYDROCARBON WITH STEAM TO PRODUCE HYDROGEN WHICH COMPRISES CONTACTING STEAM AND A HYDROCARBON IN THE PRESENCE OF A CATALYST COMPRISING NICKEL AND A REFRACTORY MATERIAL AND CONTAINING AT LEAST 0.5 WEIGHT PERCENT OF AN ADDED LAKALINE METAL COMPOUND, CALCULATED AS THE METAL, AT AN ELEVATED TEMPERATURE SUCH THAT HYDROGEN IS PRODUCED. 